Food product forming apparatus and process

ABSTRACT

Food product-forming apparatus, with a movable form-body, in which the food product is formed, and a knock out cup, which executes a knock-out-movement, that removes the food product from the form-body or according to one of the preceding claims, characterized in, that the knock out cup comprises a reservoir with compressed fluid, preferably essentially air.

The present invention is related to a food product-forming apparatus, with a movable form-body, in which the food product is formed, and a knock out cup, which executes a knock-out-movement, that removes the food product from the form-body, whereas the knock out cup comprises an at least partially permeable bottom, through which a fluid-medium can be ejected. The present invention furthermore comprises a process for the production of food products.

Food product forming apparatus are known from the state of the art. This apparatus comprises a knock out cup that is moving through holes in a rotating drum, to knock out the product, for example, food products formed in the drum. After the knock out cup hits the food product, the food product sticks at least partially at the surface of the knock out cup. In order to remove the product from the knock out cup, air, supplied at a high pressure up to 6 bar, which is expanded rapidly, is used to blast the product from the knock out cup. In many cases water is additionally needed to remove the product from the knock out cup. This apparatus has the disadvantages that it is noisy, that the wafer creates pick up problems of the product, that the product will not drop straight from the knock out and that it is difficult to divide the water evenly among several knock out cups.

It was therefore the objective of the present invention to provide a food product-forming apparatus and a process to overcome the problems according to the state of the art.

The problem is solved with a food product-forming apparatus, with a movable form-body, in which the food product is formed, and a knock out cup, which executes a knock-out-movement, that removes the food product from the form-body, whereas the knock out cup comprises an at least partially permeable bottom, through which a fluid-medium can be ejected and whereas, during the knock out movement a fluid-medium-cushion is created at least temporarily beneath the permeable bottom.

The present invention deals with a food product forming apparatus. A food product according to the present invention can be any product made of an eatable product for example meat, dough, vegetables, fruit or the like or a combination thereof. The food products may have 2D-shape, i.e. a shape whose height is constant or a 3D-shape.

This apparatus comprises a form body in which the food product is formed, for example a reciprocating plate or a rotating drum. This body comprises one or more holes, in which the food product is formed. Preferably a multitude of food products are formed simultaneously.

The food products are removed from the form body with a knock out cup, which reciprocates during one cycle from a start—into a knock-out-position and back. Preferably, the knock out cup moves free and not within a housing. The stroke length of the knock out cup is adjustable. At its bottom, i.e. at the surface next to the food product, the knock out cup comprises an at least partially permeable surface through which a fluid medium can be pressed. This surface is made for example by drilling holes into the surface, preferably with a laser, water-jet cutting and/or spark erosion. The surface is preferably a sintered porous material, for example metal, plastic and/or ceramics. More preferably, the surface is anti-adhesive regarding the product to be knocked out. The surface is connected to a source that provides the fluid medium. The fluid medium is pressed through the permeable surface. Due to the essentially homogenous flow resistance of the permeable surface, the fluid medium is spread evenly over the permeable part of the bottom.

The fluid medium is preferably air, water and/or water-vapor. The medium, especially the air can have a temperature above ambient temperature, preferably a temperature between 40 and 90° C.

During the knock out movement a fluid-medium-cushion is created at least temporarily beneath the permeable bottom. A fluid medium cushion according to the present invention is a volume outside the knock out cup, adjacent to the permeable bottom surface, in which the ejected medium has a pressure above ambient pressure. Preferably, the cushion is created by ejecting fluid medium out of the perforated bottom more preferably over an extended period of time. The cushion can be of any shape. Preferably it is a thin film, which can have an irregular shape. Preferably, this cushion is existent before and/or while the knock out cup touches the food product. This cushion at least reduces the tendency of the food product to stick to the surface of the knock out cup. Preferably, the cushion extends at least over the entire permeable area.

The cushion can be generated by ejecting the fluid medium out of the permeable bottom. The flow of the medium can continuously and/or intermittently.

Preferably the permeable bottom is a plate which is fixed to the knock out cup. Preferably the permeable bottom has a 2D-, i.e. has a constant, thickness, or 3D shape.

In a preferred embodiment of the present invention, knock-out cup comprises a sidewall with an anti adhesive coating. This coating can be for example Teflon, Miropen or a coating with a nanostructure. In general, the anti adhesive coating reduces the amount of food-product that sticks to the sidewalls of the knock out cup.

Preferably, the knock out cup is connected to at least a cleaning fluid source, that cleans the side walls and/or the bottom of the knock out cup. Preferably, this cleaning fluid is air, which has ambient temperature or is hot and/or hot water and/or hot vapor. The cleaning fluid either circulates through the knock out cup and thus for example, heats and cleans the sidewalls and/or the bottom at their product-contacting surface and/or penetrates the sidewalls and/or the bottom for cleaning purposes. Different cleaning fluids can clean different parts of the knock out cup, respectively.

Preferably, the cleaning fluid will also clean at least partially the surface of the holes in the forming body after the food product has been knocked out.

Preferably, the knock-out cup comprises a at least partially permeable sidewall through which a cleaning fluid can be pressed. This surface is made for example by drilling holes into the surface, preferably with a laser, waterjet cutting and/or spark erosion. The sidewall is preferably a sintered material, for example metal, plastic and/or ceramics. More preferably, the sidewall is anti-adhesive regarding the product to be knocked out. The surface is connected to a source that provides the cleaning medium. The fluid medium is pressed through the permeable surface. The cleaning fluid can be air, vapor, water or any other cleaning fluid suitable for food processing applications.

In another preferred embodiment, the food product-forming apparatus comprises means to release vapor and/or mist in the vicinity of the knock-out-cup, preferably in the whole knock out cup vicinity. This vapor/mist will wet the surface or the knock out cup at least partially and prevents sticking. The vapor/mist is preferably provided by ultrasonic sound means.

Another or a preferred embodiment of the present invention is a food product-forming apparatus, with a movable form-body, in which the food product is formed, and a knock out cup, which executes a knock-out-movement, that removes the food product from the form-body, whereas the knock out cup comprises a reservoir with compressed fluid, preferably essentially air. Thus, each knock out cup has its own reservoir, so that each knock out cup works under essentially identical conditions.

In this reservoir, the fluid needed to remove the food product from the knock out cup and/or to clean the knock out cup is stored and released when needed. Preferably, the reservoir is filled during its motion from the knock out—to the start-position and at least partially emptied. Preferably, all reservoirs are filled and emptied simultaneously. Preferably, the inventive apparatus has only one source to fill the reservoir.

Preferably each reservoir comprises sealing means.

The stated problem is also solved by a process to form food products with a food product-forming apparatus, with a movable form-body, in which the food product is formed, and a knock out cup, which executes a knock-out-movement, that removes the food product from the form-body, whereas a fluid-medium can be ejected via the bottom of the knock out cup and that a during the knockout movement a fluid-medium-cushion is created at least temporarily beneath the permeable bottom.

The disclosure made for the inventive apparatus also applies to the inventive process and vice versa.

Preferably, the fluid-medium-cushion is provided before the knock out cup comes in the vicinity of the food product, preferably before it hits the food product. Thus, the ejection of the fluid medium preferably starts and more preferably continues before the knock out cup hits the food product and most preferably maintains until the knock out motion of the knock out cup has reached its end-point.

Preferably after the knock-out of the food product, at least one cleaning medium is preferably ejected out of the knock-out cup, more preferably through the bottom and/or a sidewall of the knock out cup. Different cleaning fluids can be applied for different regions of the knock out cup.

Preferably, vapor and/or mist is released in the vicinity of the knock-out-cup.

The inventions are now explained according to the figures. The explanation applies to all inventions. The explanation does not limit the scope of the present invention.

FIGS. 1 and 2 show one embodiment of the inventive forming apparatus.

FIG. 3 shows an embodiment of the knock out cup.

FIG. 4 shows the interaction between the knock out cup and the food product.

FIGS. 5 a-5 f show different embodiments of the knock out cup.

FIGS. 6 a-6 d show another embodiment of the inventive forming apparatus.

FIG. 7 shows the food product forming apparatus and a transportation belt.

FIG. 8 shows the cleaning mode of the inventive food product forming apparatus.

FIG. 9 shows a contaminated knock out cup.

FIG. 10 shows a knock out cup with an anti-adhesive coating at the sidewalls.

FIG. 11 shows another cleaning mode of the knock out cup.

FIGS. 12 a-12 k show yet other embodiments of the knock out cup.

FIG. 13 shows another embodiment of the food product forming apparatus.

FIGS. 14 a-14 b show mist around the knock out cup.

FIG. 15 shows yet another embodiment of the knock out cup.

FIG. 16 shows another embodiment of the inventive food product forming machine.

FIG. 17 a-d show yet another embodiment of the knock out cup.

FIGS. 1 and 2 show the inventive forming apparatus 10. This forming apparatus 10 comprises a forming plate, which reciprocates between a filling-position in which the holes in the plate 7 are filled with the food product-product and a knock-out-position in which the formed food products 8 are removed out of the plate. The movement of plate 7 is depicted by the double arrow on the plate. FIGS. 1 and 2 depict the knock out position of the plate. The inventive apparatus 10 further comprises a knock out cup 4 which is connected to a piston 26. The knock out cup 4 moves from a start-position to a knock-out-position and back as shown by the double arrow on piston 26. The knock out cup 4 comprises at its bottom a perforated plate 11 which is permeable for a fluid medium. FIG. 1 shows the knock out cup in its start position. FIG. 2 shows the knock out cup after it has come into contact with the food product 8 in plate 7 and after it has moved through plate 7 and has knocked out the food product 8 out of plate 7. After the food products 8 have been removed from plate 7, they fall on a transportation belts and are transported to the next processing step. The person skilled in the art understands, that plate 7 can comprise a multitude of holes and correspondingly a multitude of knock out cups. The knock out cup can be driven individually or together in groups. The person skilled in the art furthermore understands that plate 7 can be substituted by a intermittently or continuously rotating drum with holes in it. In this case, the knock out cups are located preferably at the inside of the drum.

FIG. 3 shows the knock out cup 4 according to FIGS. 1 and 2. It can be seen that a permeable plate 11 is attached to the bottom of the knock out cup and that this permeable plate is fluid-wise connected to a channel 12 through which a fluid medium 13, for example air and/or vapor can be guided towards the permeable plate 11. This fluid medium 13 flows through the permeable plate and is, due to the relatively high pressure-loss of the permeable plate 11, distributed essentially evenly over the surface of the permeable plate and creates a fluid cushion 14 under the permeable plate. This fluid cushion 14 is characterized by a higher pressure than the ambient pressure around knock out cup 4 and/or by a fluid motion caused by the air ejected out of the permeable plate 11. The flow of medium 13 can be continuously or intermittently.

FIG. 4 shows the interaction between the knock out cup 4 and the food product 8. The knock out movement of the knock out cup 4 is depicted by arrow 15. Before knock out cup 4 hits food product 8 and preferably while the knock out cup 4 ejects the food product 8 out of plate 7, the fluid medium 13 is ejected out of plate 11 and creates a fluid medium cushion 14 between the knock out cup 4 and food product 8. Cushion reduces preferably prevents that food product-material sticks to the bottom of the cup. Thus, the imprint of the knock out cup and/or the deformation of the formed product during the knock out is reduced. Furthermore, the invention has the advantage, that less noise is created and that less or no water is needed to knock the food products 8 out of plate 7. The formed product 8 falls straight in the direction of the out feed belt. By achieving a straight drop of the product 8 on the out feed belt 9, the belt load can be increased, because the knock out works more accurately.

FIGS. 5 a-5 f show different layouts of the knock out cup 4, especially the permeable plate 11. All designs have in common that a fluid medium cushion 14 is created at least under the permeable part of the plate that is in fluid-contact with the fluid channel 12. Depending on the product mix and/or the product temperature different designs of the bottom part of the knock out cup can be desirable. FIG. 5 a shows a permeable plate, which is slightly embedded into the sidewalls of the knock out cup. FIG. 5 b shows a 3-dimensionally formed bottom plate 11. FIG. 5 c shows, in comparison to FIG. 5 a, a knock out cup with a permeable bottom plate that is more embedded into the sidewalls of the knock out cup. FIG. 5 d also shows a 3-dimensionally formed bottom plate 11. FIGS. 5 i and 5 f show bottom plates which are only partially permeable. The bottom plate 11 comprises a part 16 which is not permeable for the fluid medium 13.

FIGS. 6 a and 6 d show an embodiment of the inventive food product forming apparatus to produce 3-dimensionally formed food products 8. In this case, the plates 7 as well as the bottom plate 11 are 3-dimensionally shaped.

FIG. 7 shows the inventive food product forming machine. It can be clearly seen that during the knock out movement of the knock out cup 4, it is pushed through plate 7 and that a fluid medium cushion 14 is created between the bottom plate 11 and food product 8 before and while the respective food product 8 is knocked out. The food products fall on a transportation belt 9 and are transported to the next processing step. Due to the improved knock out of food products 8, the distance between plate 7 and the transportation belt 9 can be reduced, because the food products 8 drop straight downwards and not deformed on belt 9. Thus, the production rate of the apparatus can be increased and the impact on the food products during knock out is reduced.

FIG. 8 shows the knock cup during its movement in the withdrawal direction i.e. towards its start-position. This movement is depicted by arrow 17. During this upward movement, the fluid-flow of the fluid 13 is maintained in order to clean the permeable plate 11. Thus, food product particles which might stick to the permeable plate are removed, so that the knock out cup is clean for its subsequent knock out.

FIG. 9 shows a knock out cup which is contaminated with food product material 19 at its sidewall. Such a contamination is not desirable for maintenance- and hygienic-reasons.

In order to avoid the contaminations shown in FIG. 9, the knock out cup 4 according to FIG. 10 comprises an anti-adhesive-coating 20 at its sidewalls. This coating reduces preferably prevents contaminations of the sidewalls. The coating can be Teflon or a coating comprising a nano-structure or any other treatment that reduces the tendency of the food product to stick at the sidewalls.

FIG. 11 shows a preferred embodiment of the inventive food product forming machine, whereas, the knock out cup 4 is connected to a cleaning medium 21. The cleaning medium can be identical with the fluid medium 13. This cleaning medium 21 can be for example a hot cleaning medium e. g. hot air and/or hot vapor that flows through the knock out cup 4 and the permeable bottom 11. In case of a hot cleaning medium, the inventive food product forming machine comprises heating means which heats the fluid 21 preferably to a maximum temperature of 90°. The temperature depends on the product-mix used as the food product material. Preferably the knock-out cups are made of a thin material more preferably with a good thermo conductivity. The cleaning medium 21 will heat up the sidewalls of the cup and the heated walls will liquefy fat in the product which sticks to the sidewalls of the cup so that these contaminations will be removed from the sidewalls or the sticking of the contamination to the sidewalls will be prevented.

FIGS. 12 a-12 k show yet another embodiment of the present inventions i.e. a knock-out cup which comprises a sidewall with a permeable region 22. Through this permeable section 22 of these sidewalls a fluid medium 13 and/or a cleaning medium 21 can be ejected independently or together with the ejection of a fluid medium 13, 21 through the permeable plate 11. The ejection of medium 13, 21 through the at least partially permeable sidewalls 21 have the advantage, that these sidewalls are at least partially cleaned and/or that the circumference of the holes in the plate 7 are cleaned during the knock-out- and/or the withdrawal-movement of the knock-out cup 4.

This is further explained according to FIG. 13. During, the knock out movement of the knock out cup 4, the position in FIG. 13 is the ideal position to turn the direction of the movement. The flow of the medium out of the permeable sidewall 22 preferably takes place at least temporarily during movement to this position, during the turn of direction and at least temporarily during the movement back to the start position. At the bottom of the cup a cushion 14 of medium is formed to improve the discharge of the formed food product 8 from plate 7. Out of the sidewall medium 13 is discharged to prevent contamination of the sidewalls. In the position according to FIG. 13, the medium 13 also cleans the inner walls of the openings of the form plate 7. The cleaning of the inner walls of plate 7 will make the removals of food products from the forming plate easier. Furthermore, it is possible to moist the inner walls of the form plate 7 with vapor and/or mist which is blown through the permeable region 22 of the side walls onto the inner walls of the openings in plate 7.

The knock-out drive is preferably position driven. A different thickness of the form plate means and/or another height of the permeable region 22 will preferably result in a different stroke length. A position driven knock out cup for examples results in a higher production speed. In case the form plate is thinner, the movement of the knock out cup can be reduced.

FIG. 14 shows yet another embodiment of the present invention. In this case, the knock out cup 4 is surrounded with mist and/or vapor, this mist and/or vapor wets the sidewalls and/or the bottom of the knock out cup 4 at least partially and thus makes the knock out easier and contamination of the sidewalls are reduced. The knock out cup 4 according to FIG. 14 b comprises ejection means which are located at the circumference of the sidewall of the knock-out cup 4 and which eject vapor/mist 24.

FIG. 15 shows yet another embodiment of the knock-out cup 4. In this case the permeable region 22 of the sidewall is divided into two sections. One section is connected to the fluid medium 13, so that in this part of the medium is ejected out of this section of the permeable sidewalls and the permeable bottoms plate 11. The other section is connected to a cleaning medium 21 and/or to a vapor moisture and/or mist 24 in order to eject this medium out of this part of the permeable wall.

FIG. 16 shows yet another embodiment of the inventive food product forming machine. In this case, the food product forming machine comprises a vessel with a compressed medium, preferably compressed air. This vessel 1 is connected directly or indirectly via a valve 2 with each individual knock out cup 4. All knock out cups 4 are connected to a knock out bar 3 which is driven upwards and downwards by the knock out drive 5. The knock out bar 3 can also be used to fluid-wise connect with the knock out cups 4 with the compressed vessel 1. Ail knock out cups comprise at least partially perforated plates at their bottom, respectively.

FIGS. 17 a-d show another embodiment of the present invention. Each knock out cup 4 comprises a reservoir 25 for compressed air. This reservoir 25 is filled with a fluid, e.g. compressed air. The medium flows as depicted by the arrow 27 past a piston 6, which has a sealing-lip and it's circumference and flows into the reservoir 25. The piston 6 avoids that the medium flows out of the reservoir 26 as long as the pressure above the piston 6 is maintained.

The filling situation is depicted in FIGS. 17 a, c and preferably takes place while the knock out cup moves from it's knock out position to it's start position. The release of the pressurized medium in the reservoir 25 is shown in FIGS. 17 b, d. After the pressure above the piston 6 is reduced as depicted by arrow 28, the piston 6 moves upwards. This opens the connection between the reservoir 25 and the channel that connects the reservoir 25 with the bottom of the knock out cup 4 which comprises in this case a non-preferable plate 16 around which the pressurized medium flows.

The embodiment according to FIGS. 17 c and d is essentially identical with the embodiment according to FIGS. 17 a and b with the exception, that the knock out cup 4 comprises a permeable plate 11.

LIST OF REFERENCE SIGNS

-   1 Vessel -   2 Valve -   3 Knock out bar -   4 Knock out cup -   5 Knock out drive -   8 Sealing means for reservoir 25, piston -   7 Form-body, Form-plate -   8 Food product -   9 Transportation means, belt -   10 Forming apparatus -   11 Permeable bottom, permeable bottom plate -   12 Channel -   13 Fluid medium -   14 Cushion -   15 Knock out movement -   16 Non permeable bottom, Non permeable bottom plate -   17 Withdrawal direction -   18 Cleaning flow -   19 Contamination -   20 Anti-adhesive coating -   21 Cleaning medium, hot cleaning medium -   22 Permeable sidewall -   23 Ejection opening -   24 Moisture, vapor -   25 Reservoir -   26 Piston -   27, 28 flow direction 

The invention claimed is:
 1. A food product-forming apparatus comprising: a movable form-body in which the food product is formed, and a knock-out cup that executes a knock-out-movement to remove the food product from the form-body, the knock out cup includes a piston, and a reservoir located in the knock out cup, wherein the reservoir stores a compressed fluid, and the compressed fluid is at least partially emptied to remove the food product from the form-body during the knock-out-movement, and wherein during filling of the reservoir, the compressed fluid flows past the piston and into the reservoir, the compressed fluid is stored in the reservoir until a pressure drop above the piston moves the piston so that the compressed fluid can be ejected through a permeable bottom so that a fluid cushion is created at least temporarily beneath the permeable bottom.
 2. The food product-forming apparatus according to claim 1, wherein the food product-forming apparatus comprises a sealing means for the reservoir.
 3. The food product-forming apparatus according to claim 1, wherein the permeable bottom and/or a sidewall of the knock-out cup is a porous material.
 4. The food product-forming apparatus of claim 1, wherein the compressed fluid is essentially air.
 5. The food product-forming apparatus of claim 3, wherein the permeable bottom and/or the sidewall of the knock-out cup is a sintered material.
 6. The food product-forming apparatus of claim 1, wherein the permeable bottom has a 2D or 3D shape.
 7. The food product-forming apparatus of claim 1, wherein the knock-out cup comprises a sidewall with an anti adhesive coating.
 8. The food product-forming apparatus of claim 1, wherein the knock-out cup comprises an at least partially permeable sidewall.
 9. The food product-forming apparatus of claim 1, wherein the food product-forming apparatus includes at least one cleaning medium that is ejected through the permeable bottom and/or a permeable sidewall of the knock-out cup.
 10. The food product-forming apparatus of claim 3, wherein the food product-forming apparatus includes at least one cleaning medium that is ejected through the permeable bottom and/or a permeable sidewall.
 11. The food product-forming apparatus of claim 1, wherein the food product-forming apparatus comprises a means to release vapor in a vicinity of the knock-out-cup.
 12. A food product-forming apparatus comprising: a movable form-body, in which the food product is formed, a knock out cup including: i. a permeable bottom and/or a permeable sidewall, and ii. a piston, a reservoir located in the knock out cup and including a sealing means, the reservoir storing a compressed fluid, at least one cleaning medium that is ejected through the permeable bottom and/or the permeable sidewall, wherein the knock out cup executes a knock-out-movement that removes the food product from the form-body; wherein the permeable sidewall includes an anti-adhesive coating; wherein during filling of the reservoir, the compressed fluid flows past the piston into the reservoir, the compressed fluid is stored in the reservoir until a pressure drop above the piston moves the piston so that the compressed fluid is at least partially ejected through the permeable bottom to create a fluid cushion at least temporarily beneath the permeable bottom during the knock-out-movement.
 13. The food product-forming apparatus of claim 12, wherein the fluid cushion has a higher pressure than ambient pressure around the knock-out-cup.
 14. The food product-forming apparatus of claim 13, wherein the fluid cushion is free of water.
 15. The food product-forming apparatus according to claim 1, wherein the reservoir is filled with the compressed fluid while the knock-out cup moves from a knock out position to a start position.
 16. The food product-forming apparatus of claim 12, wherein during execution of the knock-out-movement, the knock out cup moves between a knock out position and a start position, and wherein the reservoir is filled with the compressed fluid while the knock out cup moves from the knock out position to the start position. 